DRAG REDUCTION ON A

PRODUCTION VEHICLE
HUSSAIN ALI
TATA MOTORS EUROPEAN TECHNICAL CENTRE
C
D
trends in Automotive industry
Major contributors to drag
Inputs to Full Scale Testing
Audi A2
How Drag was reduced
CONTENTS
PRODUCTION CAR DRAG LEVELS
C
D
change over the years
0.24
0.26
0.28
0.3
0.32
0.34
1940 1950 1960 1970 1980 1990 2000 2010 2020
Year
C
D
Production car examples
Trendline
through data
MAJOR CONTRIBUTORS TO DRAG
Base Pressures Low pressure region at the rear of the car
Wheels and wheel arches Up to 30% of cars total C
D
Cooling Air passing through cooling components
Underfloor Rough exposed car parts in direct contact with airflow
Important for the project to apply everything learned to a real life car
Everything fed into the Audi A2 and another test vehicle, Jaguar XJ
LCVTP
University
Research
Model Scale
Tests
Wheel & Wheel
Arch findings
Full Scale Wind Tunnel
Tests at Mira
Audi A2
Low C
D
When measured in the Mira wind tunnel, the Audi A2 showed a
Co-efficient of Drag (C
D
) of 0.288
Good Basic Aerodynamic shape
The launch vehicle had a C
D
of 0.25
FULL SCALE TESTING
Full scale tests carried out at Mira in Nuneaton
8m x 4m tunnel
Fixed ground tunnel
Balances in the floor
The next few slides will show how the C
D
of the
Audi A2 was reduced from 0.288 to 0.204
WIND TUNNEL TESTING
Cooling Drag
Cooling:
- All vents and intakes
closed on front end
- Total Contribution: 9%
of total Drag
WIND TUNNEL TESTING
Underfloor Drag
Underfloor:
- Foamboard and tape
- All components covered
- Total Contribution: 7%
of total Drag
WIND TUNNEL TESTING
Door Mirrors
Mirrors:
- A-Pillar Vortex
interaction
- Bluff rear face causes
drag
- Total Contribution: 5%
of total Drag
WIND TUNNEL TESTING
Wheels and Wheel arches
Wheel Spoilers
Wheel Blanking
Wheel Arch Blanking
WIND TUNNEL TESTING
Wheels and Wheel arches
Underfloor Wheel Arch Blanking
WIND TUNNEL TESTING
Base Pressure Recovery
Raising the Base pressure can reduce the Drag
Prior to Box Cavity test, diffuser angle was 7. Afterwards, optimum was 2
Box Cavity Version 1 Box Cavity Version 2
WIND TUNNEL TESTING
Base Pressure Recovery
Raising the Base pressure can reduce the Drag
Prior to Box Cavity test, diffuser angle was 7. Afterwards, optimum was 2
Box Cavity Version 3
Box Cavity Version 4
WIND TUNNEL TESTING
Base Pressure Recovery
Raising the Base pressure can reduce the Drag
Prior to Box Cavity test, diffuser angle was 7. Afterwards, optimum was 2
Box Cavity Version 5 Box Cavity Version 6
WIND TUNNEL TESTING
Base Pressure Recovery
Raising the Base pressure can reduce the Drag
Prior to Box Cavity test, diffuser angle was 7. Afterwards, optimum was 2
Box Cavity Final design
WIND TUNNEL TESTING
Aerodynamic system created
Diffuser needs a flat floor for maximum efficiency
2 Diffuser cant be obtained without the presence of a box Cavity
Box Cavity needs a diffuser to be present for best results
Interdependencies makes further refinements and drag reductions possible
Other interdependent relationships around the car
PROGRESS CHART
Progression of CD During WT Session
0.29
0.20
0.200
0.210
0.220
0.230
0.240
0.250
0.260
0.270
0.280
0.290
Standard
Production
Car
Wheel
Covers on
Flat Floor
Fitted
Front
Intakes
Closed
All Front
End Vents
and Gaps
Sealed
Door
Mirrors
removed
Underfloor
Wheel
Arch
Blanking
7 Diffuser 30mm
Front
Wheel
Spoilers
100mm
Extrusion
Tailgate
Box Cavity
2 Diffuser
Modification
C
D
Wind tunnel development
Audi A2 represents low drag tall 1-box shape
CD reduced from 0.288 to 0.204 (WIP)
Summary
Biggest contributors: Base Pressures, Cooling, Wheels & Wheel arches
30% reduction in C
D
achieved
Inputs key to successful Wind Tunnel development
CONCLUSION
THANK YOU